How We’re Expanding UK Busbar Manufacturing Capabilities for EV and Industrial Markets
Meeting the Growing Demand for Advanced Busbar Fabrication
As the UK’s demand for battery-based systems accelerates across electric vehicles (EVs) and industrial systems, William Hughes is expanding its busbar manufacturing capacity to meet the challenge. Following a number of highly successful projects last year, William Hughes Group, is investing in and expanding its busbar research, design, test and CNC fabrication operations.
With our engineering heritage that stretches back to before the Industrial Revolution, the company is leveraging its significant wire-forming expertise and deploying it in the creation of complex bus bar geometries, fabricated from ready-insulated, reel-fed stock.
Graham Burgon, sales executive at William Hughes explains: “With battery-based systems gaining a significant foothold in a variety of markets all over the world, there is growing demand from OEMs and their tier-one suppliers for precision engineered electrical components that can be fabricated to cater for complex real-estate limitations. These applications are not just for electric vehicle drivetrains, we are also seeing wider potential in marine, rail and static electrical installation, such as mining and other heavy industries.”
What Is a Busbar and Why Is It Critical for EV and Industrial Electrification?
A busbar is a highly conductive component used to distribute electrical power efficiently and safely in battery systems, switchgear and industrial installations. In EV battery packs, busbars manage high-current connections between battery cells, while in ICE support systems, they serve in low-voltage circuits and control systems.
Across sectors such as marine, rail, mining, and electric automotive manufacture, the design and reliability of these assemblies are critical to ensuring safety, thermal control, and power efficiency.
Why Choose CNC Busbar Manufacturing Over Stamped Alternatives?
Traditional busbar fabrication relies on stamping, followed by forming and insulation. While effective in high-volume production, this method can be costly and inflexible. These limitations make bending and forming from reel-stock a more efficient and viable process, particularly in industries like electric vehicle design, where space constraints and rapid design iterations demand agility.
William Hughes’ technique uses advanced CNC technology to precisely form pre-coated copper stock in such a way that the existing insulation remains completely viable along the length of the bar. The technique has been researched and developed to exploit the fact that straight copper bar stock can be more easily coated than bar that has already been shaped.
“Bus bars are a natural progression from our wire and spring capabilities,” Burgon explains. “Indeed, the fabrication techniques and processes are similar, albeit with stock materials with a different cross-section. We are also able to leverage our extensive R&D capabilities. In addition to our existing successes in the electric vehicle market, the growing economies of scale in the global mobile battery market will expand battery and low-voltage applications, which in turn will drive demand for ancillaries such as bus bars - but only if they match the strict quality and complexity criteria.”
William Hughes can create complex bus bars to order.
Where Are Custom Busbars Used Beyond Electric Vehicles?
Busbar systems are now widely used in:
- EV battery and drivetrain systems
- ICE vehicle low-voltage architecture
- Marine and rail electrification
- Mining and static industrial power systems
Each use case presents challenges in terms of size, heat resistance, vibration, and layout, challenges our engineering team is well-versed in overcoming.
How Can UK Busbar Manufacturers Support Rapid Prototyping?
William Hughes has invested in rapid busbar prototyping capabilities within its UK facility. Using our CNC fabrication line, we’re able to produce custom busbar sub-assemblies in small batches or one-offs, supporting client innovation cycles.
Our engineering teams work directly with OEMs and Tier 1s to optimise each unit for performance, manufacturability, and long-term durability.
Busbar Manufacturing & Design FAQs
What materials are used in high-performance busbar manufacturing?
We primarily use pre-coated copper due to its conductivity and compatibility with CNC forming, ensuring insulation remains intact during shaping.
How are CNC busbars different from stamped alternatives?
CNC-formed busbars from reel stock allow for complex shapes, cost savings on tooling, and fast adjustments—ideal for EV and industrial R&D projects.
Can William Hughes fabricate busbars for both ICE and EV systems?
Yes. Our components support both electric and combustion engine vehicle systems, as well as static and mobile industrial applications.
What industries are increasingly using busbars?
Beyond automotive, we see strong demand in marine electrification, rail systems, heavy industry, and off-grid battery storage solutions.
Why choose a UK busbar manufacturer?
UK-based fabrication ensures reliable quality control, shorter lead times, and closer collaboration with your engineering team throughout the product lifecycle.